Hydrogen fluoride alkylation process



J. o. `lvERsJN HYDROGEN FLUORIDE ALKYLTIN PROCESS Nov. 13, 1945,.

Filed Sept 2l, 1942 QNMN @SNN MN www.

atented ov'c 13, 1945 STATES rArNr HYDROGEN FLUoas am raocass rios `lohn 0. Iverson, Chicago, Ill., assigner to Universal Oil Products Comp poration oi Delaware any, Chicago, Iii., a cor- Applic'ation September 21, 1942, Serial No. 459,110

3 Claims.

This is s communicants-part of my Capena-- ing application Serial No. 404.607, filed July 30,

, lariy concerned with an improved method for 'conducting the regeneration of used hydrogen v fluoride catalyst.

The reaction of isoparafiins with oleiins to produce higher molecularweight isoparatiinic hydrocarbons is well-known method for the manufacture of high antiknock motor fuels. Various catalysts such as a metal halide with a halogen halide promoter, phosphoric acid, and sulfuric acid have been proposed for this reaction. However, catalysts which contain hydrogen iiuoride as their essential active ingredient possess considerable advantage over any of the previously suggested catalysts. For example, when using a hydrogen fluoride catalyst the alkylation reaction may be conducted at' a substantially vhigher temperature than it is feasible with sulfuric acid catalysts which induce undesirable side reactions at higher temperature. Moreover, hydrogen iiuoproducts may be recovered readily and returned -to the'proeess ior reuse. Furthermore, the used decreases the eective hydrogen iluoride concentration to such an extent that the alkylating activity of the catalyst begins to decline. By withdrawing a portion of the contaminated cataiyst from the system either intermittently or continuously and replacing the withdrawn eatalyst with fresh or regenerated catalyst of high-v er hydrogen fluoride concentration it is possible ride which dissolves in the' hydrocarbon reaction (Cl. 26d-683.4)

polymers. A portion of the overhead stream containing hydrogen iuoride may be returned directly to the alkylation step while another portion is preferablysubjected to a water removal step and the driedA hydrogen iiuoride is also returned to the alkylation step. The water removal is readily effected by subjecting a portion of the overhead hydrocarbon hydrogen fluoride water stream to fractionation in a second fractionating column. Substantially anhydrousf hydrogen fluoride may be recovered overhead while a hydrogen iluoride-water mixture is 'withdrawn from the bottom of the fractionating column.

It is the principal object of the present invention to overcome certain dimculties which are inherent in the above'described method of regenerating used hydrogen iiuoride catalyst.

In one specific embodiment the present invention comprises an improved process for the regeneration of a. used hydrogen uoride catalyst which includes the steps of subjecting the used hydrogen uoride catalyst to a first fractionation wherein light hydrocarbons are removed overhead, subjecting the bottoms product from said nrst fractionationl to a second fractionation step operated at a substantially lower` pressure wherein an overhead distillate comprising essentially hydrogen iiuoride and water is separated from a bottoms product comprising essentially higher boiling hydrocarbons, returning a. portion of said last mentioned overhead distillate to the catalytic reaction step, subjecting another portion of said last mentioned overhead distillate to a third fracti'onation step wherein substantially anhydrous hydrogen fluoride is removed overhead from a bottoms product comprising a hydrogen fluoride-v water mixture. and returning said substantially anhydrous hydrogen fluoride tothe catalytic reaction step. When a used hydrogen fluoride catalyst is regenerated by fractionation to separate hydrogen' uoride and water from higher boiling organic contaminants, considerable 'diniculty is often exto maintain the desired level or catalyst activity. l

Regeneration of the contaminated catalyst may be most readily accomplished by a heating and distillation .step or steps. The`catalyst may be introduced into a. rst fractionating column wherein an overhead stream comprising hydrogen iluoride, water, and iight hydrocarbons is sepa.-

Arated from a' bottoms product which consists loriyolboilingorgenicmateriuisnd perenced because the usedcatalyst usually contains appreciable amounts of dissolved lower boiling hydrocarbons.

tilled over with hydrogen uoride and water, and as a result it is necessary to employ substantially high pressures, e. g. of the order of pounds In the fractionation stepthese high vapor pressure hydrocarbons are disi pumpltolinel.

effect decomposition ci the organic complexes in the used catalyst and larger reboiler surfaces may be required. Moreover, the'danger of severe corrosion diiculties is increased by the use of higher temperatures.

Several methods may be employed to circumvent this dimculty, e. g. the used catalyst to be regenerated may rst be scrubbed or contacted with a heavier hydrocarbon or hydrocarbon fraction which will extract the dissolved lower boiling hy drocarbons.

Another method which may be employed consists in adding a higher boiling hydrocarbon or other material to the overhead stream from the regenerating fractionator whereby the high vapor pressure caused by the pressence of light hydrocarbons is counteracted at least in part and the total vapor pressure of the mixture is sufficiently decreased to permit condensation without maintaining undesirably high pressures in. the condensing system.- The heavier hydrocarbon to be added may conveniently comprise the a1- kylation'reaction products or anydesired fraction thereof, e. g., the fraction boiling above 300 F.

In the present invention, however, the diilculty caused by the presence of dissolved light hydrocarbons in the contaminated catalyst is overcome largely by the use of an additional fractionating step as hereinafter describedY in greater detail. The used catalyst is rst subjected to fractionation for the recovery overhead of light hydrocarbons only, although a relatively small proportion of hydrogen fluoride will usually'be distilled over with the light hydrocarbons. The residual mixture comprising hydrogen iiuoride, water, and organic contaminants is withdrawn from the bottom of this fractionating column and, being substantially free of dissolved light hydrocarbons, it is now subjected to regeneration by fractional distillation in the manner hereinbefore described but ata substantially lower pressure and without drogen iluoride from time tank 9v is withdrawn through line Ill and valve Il, through cooler I2, wherein a portion of the heat oi reaction is removed and thence through line I3 and valve I4 into recirculating pump 9. 4The combination of time tank '9 with thelemulsion recirculating system comprises the reaction zone.

A smaller portion of the emulsion of hydrocarbon and hydrogen uoride from time tank 9 passes the complications which arise when light hydrocarbons are present in the overhead distillate.

The accompanying drawing is. a .diagrammatic 'illustration of -an arrangement of apparatus suitable or conducting the present invention. Further advantages and modifications oi my invention will become more apparentin the following description of the drawing.

Vessel 9 shown in the drawing is the alkylation reaction zone o! the system case a so-called time tank containing a pluralduce turbulent mixing of the reactants and catalyst. It will be apparent that any convenient form of apparatus may be employed asa reaction zone, for example, a mechanically agitated reac-V tion zone. It is only necessary that the reaction zone provide sufficient agitation to obtain intimate contacting ot the hydrocarbons and catalysts.

Referring to the drawing, a hydrocarbon charge which may comprise essentially isobutane, butylenes and normal butane is passed asa liquidunder pressure through line I, valve 2, and charge The charge ls combined in line 4 with a recycled isobutane fraction from line 5I. The combined feed from line 4 is then admitted to line I3 containing a recirculating emulsion o! hydrogen iluoride and hydrocarbons. The resultant commingled mixture is then passed through pump 9, line 1 and valve 8 to time tank 9, in which the interaction ol oleiinic and isoparaillnlc hydrocarbons is substantially completed. A large portion the emulsion of hydrocarbons and hyand comprises in this ity of oriilces or internal bailles designed toprowherein hydrogen iluoride catalyst is settled out into a lowerL layer and withdrawn through line I8 and valve I9 as shown later. The hydrocarbon from alkylation settler I1 passes through line 2li, valve 2l, pump 22, and line 23 containing valve 23' to fractionator 24. The vapors from fractionator 24 pass through line 25 and valve 26, condenser 21, andline 29 containing valve 29 to receiver 29. This fractionation column removes the propane and dissolved hydrogen iluoride from the product. However, it is necessary to supply substantially large amounts of reflux in order to remove all of the dissolved hydrogen fluoride. This reflux is'returned from receiver 29 through line 30, valve 3l, pump 32 and line 33 containing valve 33 to the upper portion of fractionator 24. Any gaseous propane that may be present may be removed through line 34 and valve 35. The hydrogen fluoride which separates as a heavy lower layer in the bottom of receiver 29 will be withdrawn through line 39 and valve 31 to be returned to the process as shown later.

The reilux condensate from yfractionator 24 is withdrawn through line 38 and valve 39 and directed to a second fractionation step in fractionator 40. From this fractionation the overhead product,'consisting mainly of isobutane, is withdrawn through line 4I, valve 42, condenser 43, line 44 and valve 44' to receiver 45. Anynoncondensable gases present will be removed through line 49 and valve 41. The liquid isobutane passes through line 48, valve 49, pump 50, line 5I, and valve 52 to the beginning of the process where it is combined with the charge in line 4. A product consisting of n-butane and alkylate is withdrawn through line IIB and valve II1.

In order to maintain the catalyst activity in the reaction system, a small portion of the catalyst is continuously, regenerated as hereinafter described. A stream of hydrocarbon and hydroy gen fluoride emulsion is with'drawn from emulsion circulating line 1 through line 53 and valve 54 to a supplementary emulsion settler 55, wherein the hydrogen fluoride settles out. The hydrocarbon layer substantially freed from hydrogen iluoride is returned to the reaction zone through line 59 and valve 51. Hydrogen fluoride catalyst containing organic contaminating materials is passed from emulsion settler 55 through line 5l and valve 59 to lractionator 90 wherein low boiling hydrocarbons and, in some cases. a small amount of hydrogen fluoride are taken overhead through line 6I, valve 92, condenser 93, line 94 and valve.95 to receiver 99. 'I he hydrocarbon condensate in receiver 99 is withdrawn though line 12 containing valve 13 and is th'en introduced into line 14 whereby it may be returned to the @essere returned by gravity or by pump b9 through line l and valve 'li to column tu las reux. Ordi narily column @Il will be operated at a pressure only slightly lower than the discharge pressure of pump 6, for example. about 150 pounds per square inch.

In certain cases it may be desirable to introduce isobutane or other isoparaiiins from an extraneous source into column 6o at some point below the catalyst feed inlet, for example. through line il@ and valve H5, in order to aid in ,the regeneration ofthe catalyst and in lthe decomposition of the organic complexescentained in the used catalyst. The temperature of the liquid in the column bottoms and the time of residence can be adjusted to control th'e extent of regeneration accomplished in thiscolumn. The isobutane lreacts with the hydrogen fluoride complexes such as alkyl iiuorides, and higher boiling alkylation products are obtained. which are withdrawn through line l and eventually are withdrawn in the organic diluent stream removed from column il through line le. The released hydrogen uoride is recovered overhead from column 1l. In certain cases it may be desirable to remove the dissolved light hydrocarbons from only a portion of the catalyst to be regenerated in which instance part of the catalyst layer from settler 55 passes through line 58, line ilu, valve H9, and line 20 to column ll.

When the low boiling hydrocarbons dissolved in the used catalyst comprises appreciable quantities of isobutane, a. portion or all of this isobutane may react with the used catalyst in co1- umn Sil in the manier above described and thus be converted to higher boiling constituents which will not distill overhead during the :unal regen' eration of the used catalyst. Other dissolved light hydrocarbons present may-be removed overhead in column Bil. It may be desirable under ,certain circumstances to replace or supplement the alkylation stage of the process. The method hereinbefore described oi adding a heavier iiydrocarbon to the overhead distillate from colv or constant boiling mixture, of water and hydrovalve lol, pump los, line los and valve iii to v linel'lt to be returned tothe reaction zone., A

v portion of the hydrogen fluoride is returned to bons to higher boiling materials which will not clistill overhead when the catalyst ls regenerated by subsequent fractionation.

The bottoms product from column tu is withdrawn through line l5 containing valve 'it and is introduced through line it@ into fractionating column ll, wherein substantially complete regeneration or any desired degree of regeneration of the contaminated catalyst is accomplished., This column may be operated at some lower pressure than column Bil and at a temperature such that allthe hydrogen fluoride and water mixture is completely vaporized and the organic .complexes such' as organic uorides are decomposed leaving only a high boiling polymer-like hydrocarbon to be withdrawn through line 'is and valve i9 as a bottoms product. The overhead distillate from column Il passes through line 8o, valve di, condenser b2, line 83 and valve 8d to receiver ab. Non-condensable gases may be vented through line 85 and valve 8i. The liquid condensate from the column as reiiux through line H2 valve l H3. The combined streams of hydrogen uoride from, lines los, 3S. and le are returned throh .i

line 'M and line 5d to line i3 and the reaction zone. Fresh hydrogen duoiride catahrstx may be added when necessary through line im land valve lio.

It will be apparent that the feature ot'my invention resides in an improved method for the regeneration of contaminated hydrogen iiuorlde catalyst. Therefore, it is not intended to limit the allsylation reaction system proper to any par# ticular'arrangement of apparatus. The fraction ation of the reaction products and the recovery of dissolved hydrogen fluoride may beeected in numerous modilcations or the now shown in the drawing.

By the term hydrogen uoride catalyst, which is used throughout this specincation and ap pended claims it is intended to include catalysts `whose essential active `redlent is hydrogen uoride. it is within the scope or my invention, therefore, to employ hydrogen uorlde which contains minor amounts of other substances, for

' example,'water or promoters such as boron trlhigh as about 10% water present in the .iatalyst,

Excessive dilution with water must be avoed., however, since it will result in a declinein almlating activity of the ce i f- The aimlation of isopara with 'ole in .the presence of a hydrogen iiuoride catalyst is effected at temperatures of the order or from about 9 F. to about 208 F. although amore preferable range is from about 50 F. to about 150 F. Under certain circumstances even lower temperatures may be employed. The pressure in.

receiver 85 is withdrawn through line 88 and Y valve 89 to pump 9@ whereby a portion of the condensate may be returned through line si and valve 92 to column 'il as reux. Part of the purifled liquid hydrogen uoride is withdrawn from line 9i through line 'It and isth'en divided into two streams, the one passing through line St and valve se to fractionator 95, and the other contilnuing through line 'le into line 5t to be recycled to although in certain cases it may be desirable to extend this range in either direction. As is well-f known in the lation' art an excess of isos par over oleiins should be maintained in the alkylation zone at all times, e. g., from about 4:1 or 5:1 to about 10:1 or even higher.

I claim as my invention:

i. In the alkylation of isoparaillns with olens in the presence of a hydrogen fluoride' catalyst wherein contaminated catalyst is removed from the alkylation system and subjected to regeneration. for. the recovery of purified hydrogen fluoride suitable for reuse in the alkyiation step,

the improvement which comprises fractionating said contaminated hydrogen fluoride in a rst fractionation zone for the separation of low boiling hydrocarbons dissolved in said contaminated catalyst, subjecting the bottoms product from said first fractionation step to further fractionation in a second fractionation stepwherein an overhead distillate comprislngessentially hydro@ gen fluoride and water is separated from a b0t` toms product comprising essentially higher boiling hydrocarbons. returning a portion of said overhead distillate to the alkylation step, subjecting another portion of said overhead distillate to fractionation in a third fractionation step wherein substantially anhydrous hydrogen fluoride is removed overhead from a bottoms product comprising a hydrogen fluoride-water mixture, and returning said substantially anhydrous hydrogen fluoride to the alkylation step.

2. The process of claim 1 wherein said separated low boiling hydrocarbons are returned to A I the alkylation step.

3. The process of claim 1 wherein said second fractionation step is operated at a substantially lower pressure than said first fractionation step.

JOHN O. IVERSON. 

